Prefabricated concrete form



Dec. 7, 1948. 5, WEST 2,455,455

PREFABRICATED CONCRETE FORM Filed Dec. 12, 1946 2 Sheets-Sheet l INVENTOR.

Adan gay Patented Dec. 7, 1948 UNITED STATES PATENT OFFICE PREFABRICATEDCONCRETE FORM Paul'B. West, Newark, N. J.

Application December 12, 1946, Serial No. 715,839

12 Claims.

This invention relates to' improvements in form structures adapted foruse in the production of concrete walls, roofs, floors and other partsof concrete building erections; and the invention has reference, moreparticularly, to a novel construction of prefabricated form structureready to be transported to and set up at a building site.

This invention has for its primary object to provide novel form unitstructures of such design that the same may be prefabricated in a shop,whereby to provide complete unitary form units ready to be transportedto a building site, and there set up preparatory to application theretoof concrete or like moldable mixture for the production of a desiredbuilding wall, floor, roof or other part of a building construction,each form unit including form walls for shaping the applied concreteinto monolithic wall and stud or like formations, together with properlypositioned and related elements adapted to reenforce the concreteformations, as well as lathing for supporting plaster facings atinterior sides of the finished wall or other concrete formation.

The invention has for another object to provide a novel prefabricatedform structure of the kind stated wherein the form walls compriserelatively inexpensive sheet material, such, e. g., as corrugatedpaperboard or the like, which may be left in the finished concreteformation; said sheet material being so folded upon itself as to providea strong and substantially rigid self-trussed form wall assembly, wellable to withstand and support the stresses and pressure of the concreteapplied thereto, especially when the application is made by a gunningmethod, while at the same time, providing for suitably shaped stud orlike molding cavities, whereby the finished concrete formation isprovided with stud or like portions which are unitary therewith; thesheet material being also arranged so as to provide insulating air cellswithin the wall or other finished concrete formation.

The invention has for a further object to provide a prefabricated formstructure, the form wall portions of which comprise folded sections ofsheet material, such as corrugated paperboard or the like, which arecompleted by joining marginal portions thereof by novel interlockingjoint formations; said joint formations being, in turn, secured againstseparation or disruption by easily applied wire stapling.

The invention has for a still further object to provide novel means forboth tying its form wall sections together in aligned relation, while,at the same time, providing means for supporting con- 2 cretereenforcing elements in fixed spaced relation to the outer face wall ofthe form to which the concrete is to be applied.

The invention has for another object to provide a novel prefabricatedform structure as above characterized which is especially well adaptedto receive gunned application of concrete thereto.

Other objects of this invention, not at this time more particularlyenumerated, will be understood from the following detailed descriptionof the same.

An illustrative embodiment of the invention is shown in the accompanyingdrawings, in which Fig. 1 is a perspective view of the novel,prefabricated form structure according to this invention, with partsbroken away and in part section; and Fig. 2 is a vertical crosssectional View of the form structure, taken on line 2-2 in Fig. 1.

Fig. 3 is a fragmentary skeletal perspective view of an assembly ofparts of the form structure omitting the form wall sections.

Fig. 4 is a fragmentary perspective view of a joint formation of theform wall sections.

Fig. 5 is a fragmentary perspective view showing a base or groundnailing block at the foot of a form wall section.

Fig. 6 is a fragmentary perspective view of corrugated paper board whichconstitutes the preferred sheet material from which the form wallsections are produced.

Similar characters of reference are employed in the hereinabovedescribed views, to indicate corresponding parts.

The novel form structure according to this invention comprises aplurality of preformed form wall sections made by folding and assemblingsheet material, preferably corrugated paperboard of the kind shown inFig. 6, whereby to produce substantially right triangular units A andinverted U-shaped units B.

The right triangular units A each comprise a face or front panel I0 andend panel H extending right angularly from one perpendicular side ofsaid front panel, and an angular rear panel I2 which extends from therear perpendicular side of said end panel to converge upon theoppositeperpendicular side of said front panel. Said end panel and rear panelare preferably unitary, and their adjoining portions are scored toprovide perpendicular fold lines, whereby, when relatively folded intoultimate angular relation, to provide at the juncture thereof acomparatively narrow rear face portion l3 disposed to lie in a plane 3parallel to that of the front panel l0. Mounted on the inner surface ofsaid rear face portion l3, to extend perpendicularly therealong frombottom to top thereof, is a sheet metal strip I4, from which isoutwardly struck a series of longitudinally spaced prongs l5. Saidprongs [5 project through the body of said rear face portion l3 so as toproject from the outer surface thereof, whereby tozserve' as-means forattaching lathing-v or plasterboard to the rearfaoe of theformstructure,as will subsequently appear. Formed by folded portions of theperpendicular meeting; sides of the front panel I0 and .endipanell ls ajoint structure by which said panels are'united'. Said joint structurecomprises an inturned:ma1e.-- joint member it which extends from thefront panel l0, and an inverted, outwardly opem U-'- shaped female jointmember I! which extends from the end panel II. Said joint structure isassembled by inserting. the male joint member [5 into; and 'within theembrace v of .,the. female joint member l1," and thereupon securingthese parts. together.by engaging wire staples, Wtherethrough at.suitably spaced Lintervals. along the length thereof Theadjoiningonvergent. perpendicua lar sidespf the front. panel .I 0 and rear panel1 l 2" are respectively provided with an inturnedmale joint. member l9.and an out-turnedmaleyjoint member. Ztljwhich are disposed :in lappedcontiguous; relation, andjwhichform parts of a V joint structure wherebya right'triangular form wall" unitAis joined to anadjacent inverted;U'-'shaped r wa unit "Bias.w llisub qu st pe r-- The outwardly open,inverted U-shaped' units B each. comprise a rear panel 2| of suitablewidth, .from. the respective perpendicular sides of which.extendoutwardly projecting side panels 22; Sa djsid panels 22, are.unitarLWith the rear panel ..2l intermediate fold defining; scores. be,ing provided whereby the .former ,may'befolded' relative to the latterinto. thedescribedj outward extension therefrom... Mountedpn the innersurface of. saidnr'ear, p.anel' .2l,1 to.. extend.perpendicularlytherealong intermediate its sides. and fromtop. to.bottom, thereon is. another. sheet metalfstrip... ltithfeLprong I51,0f"Which project, through andexteriorly of the body of .saidlurear panel2],. whereby to likewise serve for attaching lath'ingorplasterboarwtothe. rear. face of the. form :stn1.cture. Formed .byfolded. parts..- of .the. respective forward marginal pprtionsofjth'eside panels 22 ar e outward1y open, U.-sha.p edj femalejointjmembersgzij To arrange the form wall units ,AgandwBjin" operativeassembled relation, pairs of the units A are. adjoinedwith theirend'panels. I I opposed and'gabutted, whereupon units are interposed.betweenthus relatedfpairs of .units A;.and joined thereto; such.assemblin relation; being. con, tinued until a desired. length of .1formstructure is obtained." The meetin sides.of.the unitsAfl. and B,are.join ed together.byinsertingJhe contiguousmale, joint'mem'berslllrfindjzflfof a unit... A .into and within theembrace.,of.jthe..female. joint member 2.3.iat the side .of an. adjoining unit B, and thereupon securing these, parts together by. wire,staples, similar. to the. above mentioned wire. staples 1 l 8, andsimilarly. applied along. the. thus. formed jointstructure at.desirably. spaced; intervals. f

The form. wall units are proyided with...suit=. ablylocated.coupler.loops. 24 arranged,,.toypro ject exteriorly from the.forwardface or front. of the. assembly thereof- These .coupler loops,.inone satisfactory form thereof, comprise wire formations made of doublinga length of wire upon itself into a loop, the legs of which terminate inangularly and oppositely extending foot pieces 25. The foot piece endsof said coupler are inserted within the female joint members I! and 23,and then the coupler loops are secured to the joint formations bycertain of the staples [8 which are disposed to bridge the coupler looplegs :(see Fig 4-);2 The coupler :loopszl l are positinned: inconnection with ,..the. respective form wall units A and B so as to belaterally aligned in,a plurality of horizontally spaced rowsextendingacross theiront of the assembly of said units,said---rows-beingarranged in suitably vertically spacedqapart relation.

When a desired member of form wall units A and--B-liave been-assembledin the mutual relatiomabovedescribed, a rigid steel lock bar or strip 26of suitable width, thickness and length is. threadedthrough eachhorizontal row. of coupll'iloops zdi lock .bars or strips .not.

only tie.the.;assembled form wall units .togethen' beddedinthe,concretawhen the latteris. applied'..

to thelform structure andjthussoas to .provide.

a strong reenforcingmeans. .for.. the... wallimass,

which is. formed.by,.t11e applied .concrete.

One illustrativeform ofthe-reenforcing means...

lastrefe1.'r,ed...to,v as. .showrmcomprises.suitably. sized panels. orgrids zfl.formedgby suitably interconnectedipeltpendicular and,horizontal metallic. bars, thei perpendicular bars. being affixedto..the.. outenedges ,of .thedock ,bars.,.or.. strips, 26.. in anysuitable ,manner, as..by..tack welding ,the .same to,

the latter. Adjoining, ends. .of the thusapplieds reenforcing panels.or. .grids-,2], .may; be. tied to.- gether. bynwiret ties; B..-if sodesired,

It. will.-.-be.--observed .that the, U. .-.shaped. form wall units 13-,which .arespaoed at selected intervals .along;.the..,form'wall..struc.ture..by ..the.- inter: vening units .asbeirie; outw rdlyopemform mold. .cavitiessinnwhich the. concrete,v when appl ed tth'eform structure: mayt wh y .t i.

produce suitablyspaced .stud oralike formations S. which ,are, unitary.with the. wall formed, by, appliedzconcrete, and. which,.are., disposedto .extench rearwardlyt-f rom .the. wall .mass.. Meansis'.

"provided 1 for, suDPOrt A I reenforcingv elements.

within. said..mold. cauitiesi,provided 3 by the. form.

wall..-units.-B; so. that. said. elements. will .be imv bedded. in.the... applied; concrete. To this end each; form. wall...unit..B,., isrovided...with t a ..rod..

hanger;.,means. adapted. to support. and... position. a metallicreenforcing rod 29 for perpendicular. extension! through. the.interior... of the. .wall form unit .3. In an illustrative. form thereofas shown. said .mdhangier means. comprises --.-a bridge. piece,stvharing,,susnension..hook portions- 3 l... upstancb.

ing from .its...respectiye. ends;..said.1bridgepie e having at..least1'. one fopening through which the. reenforcing,rodl29,'.inayibeeng= .edl he $115.:- pension .hooksportions .31.are....respectiv.el engaged over the top marginal portionspflthehsideS0,, 30. spans.,the.-,int.erior,;oiJsaid unit..-

Additional ;,means; is provided-Zion holdingithe, reenforcing.l'ods..2am .desired.perpendicular ,ex-,. tension and position within theinterior of the form wall units B. Said means comprise forwardlyextending tie-members 3.2 for interconnection between the reenforcingrods 29 andthe lock bars or strips 26. Said tie-members 32 preferablycomprise wire formations each provided with a rear hook portion 33 toengage around a reenforcing rod 29 and a forward hook portion 3a toengage around a lock bar or strip 26. Said tie-members 32 serve toretain the reenforcing rods 29 against lateral and rearwarddisplacement. The rod holding means further includes rearwardlyextending tie-members 35 for interconnection between the reenforcingrods 29 and an adjacent metallic strip it with which each form wall unitB is provided. Preferably, said tie-members 35 also comprise wireformations each provided with a forward hook portion 36 to engage arounda reenforcing rod 29 and a rearward lateral arm 31 to engage in aretaining knuckle or bearing 38 with which the adjacent metallic stripI4 is provided. Said tiemembers 35 serve to retain the reenforcing rods29 against lateral and forward displacement.

To complete the prefabricated form structure, lathing, plasterboard orlike inner wall face means or component, is secured to and in coveringrelation to the rear side of the assembled form wall units A and B, thesame being secured in place by the penetration therethrough of theprongs l5 of the sheet metal strips I4 with which said units areprovided, the free ends of said prongs being thereupon clinched over andin holding relation to the applied lathing, plasterboard or the like(see Fig, 2). For example, as shown, panels 39 of wire mesh, expandedmetal lath or the like, are thus secured to the rear face of the formstructure, whereby, after a concrete wall or the like is produced by aidof the form structure, the same serves to receive and hold an interiorfinishing coating or plaster or the like (not shown).

In making up the wall form units A and B from the preferred corrugatedpaperboard, said paperboard is so disposed that the corrugations thereofextend horizontally or transverse to the perpendicular height of theform units. As thus disposed,

the corrugations are best arranged to stiffen the units so that theyefficiently resist the stresses and pressures of the applied concrete,both during application and thereafter, while at the same time enhancingthe self trussing efficiency of said units due to the shape thereof.

The corrugated paperboard or other similar sheet material from which theform wall units A and B are produced, should generally be impregnated orcoated inside and outside with a suitable waterproofing material,whereby said units provide, with respect to the finished wall or thelike, a very efficient barrier between outer and inner sides of thelatter, against penetration of the wall or the like by moisture.

The described form wall structure may be made up in advance of use in ashop or erection plant as complete fabricated sections of suitablelength and of one storey height, ready to be transported to the site ofthe building in connection with which use thereof is to be made. Whendelivered at the building site, the prefabricated form structuresections can be quickly stood up and assembled on the foundation orother footing therefor ready to receive application of concrete thereto.If desired, the lower ends of the form wall units may be provided withnailing blocks 40 for footing the same on the foundation or othersupport or ground, the units being fastened to said blocks 40 by passingnails 4| through the unit material and contiguous sheet metal stri s I4and driving said nails into the blocks.

A plate 42 is superposed upon the top of the erected form wallstructure, and is provided with stud bolts 43 and fastening nuts 44.Said stud bolts are provided with suitably enlarged lower end portions45 which are positioned to depend into interiors of mold cavitiesprovided by the form wall units B, so that the same will be imbedded andanchored in the concrete, when the latter is filled into said cavities.

The upper margins of the mesh panels 39 are preferably dimensioned toextend somewhat beyond the top of the form structure, so that the uppermarginal portions of said panels may lap theplate 42, and then besecured thereto by suitable fastening means, such as by staples 46 (seeFig.2).

It will be noted that by reason of the provision of the coupler loops'24, which receive the lock bar or strip 26, at the joint structures ofthe form wall units A and B, in addition to the firmly securedconnection of the lathing 39 to the rear portions of said units A and B,and the inter-tying of the lathing 39 and lock bar or strips 25 by thetiemembers 32 and 35, a form structure of great strength and rigidity isassured, wherein all said parts mutually cooperate to sustain thestresses and pressures of the applied concrete.

After the form structure is in place, the concrete C may be applied tothe front side thereof so as to be shaped thereby, while at the sametime imbedding the reenforcing material 21 and 29 in the appliedconcrete mass. Due to the character and qualities of the form wallstructure, the same is especially well adapted to receive application ofthe concrete by a gunning method; although by use of a retaining wallerected in front of the form structure, the concrete may, if desired, beapplied by a casting or pouring method. Since the form structure remainsin the wall or other concrete formation it will be seen that the hollowform wall units A will provide insulating air cells within the finishedWall or other formation.

Owing to the character of the form wall units A and B, it will beobvious that form structure sections may be relatively spaced andarranged, or-parts thereof easily cut away and shaped at desired pointsfor provision of window, door, or other desired building openings.

I am aware that changes could be made in the above describedprefabricated form wall structure without departing from the scope ofthis invention as defined in the herefollowing claims. It is thereforeintended that all matter contained in the foregoing description or shownin the accompanying drawings shall be interpreted as illustrative andnot in a limiting sense.

I claim:

1. A prefabricated form structure for the purposes described comprisingan assembly of hollow form wall units made of folded sheet material,certain of said units being of substantially claimzd uvherein.:.thesheet material fromwwhich .1 I

thesform-cwall. units;altermaddlcomprisesewatera prooltedecorrugated;paperboard, ,said ipaperboardsl being'zsozdisposed; that. ;thecorrugations :.theree[:.-. extend;;transversely across the panelscomprising; saidiunitsr 511A prefabricated formStIllCtuI'evfOD;thEJUP-lr poses: described;.comprisinggan .assembly; of.-hol-;=- lowzaform wallunits made of: folded rsheet: ma.-. terial,certain of; said-.unitsbeing .;of substantia1ly rightctrian lllar: crosssectionand-other ofiesaid 3O unitsgrbeing; ;of;; substantially;U..-shape d-., cross: seer-.- tiorr; said-fri htitrian ular units being:arranged in pairse-witlrptlreirsroblique:Dane1srearwardly -,-pre.-.-sellllfiduandcgtheil; end panels abuttedwherebyq to.fonwardmpresent-their ,remaininglprefront panelsin .a-,,commona--plane,l a .U..-shaped;unit. being. dise posed; intermediate-1adjacent. pairs.I of athus-v ar-.-- ranged right ptriangulareunits-vwith its: open: faee1- disposedinrtheplaneqof said front; panels- 0t thelatterrunits, marginal .-portions.,-of-.:-said'= thus ad-;--

joinett;:un-its being folded -and-interen a ed 1307- provide -unitingjointestructures; l wire1--stapleS-eX'- tending; through said -.j oint.structu-resa-tmsecureez together the; components athereofi; loclsEbarSkdiS? posed across the front of the thus assembled unitscoupler:loops rooted: in said-v unit: joint structures and :securedvthereto:bycertain ,of. said :wireesta... ples; saidcouplerlloops projecting from.the errant... face tOfriSflid assembled units: so as to .receiveitheo.lock bars and thus secure=the-units thereto,,-mee!-- 5Q tallic mesh forconcreteireenforcement.secured'to. thelouterredges of said lockloars toextend across theriront, of the. assembled units 1 in; outwardly spaced.relation .thereto; an.-inner;;wal1- -;medium disposed lacrossthenrearrof: theassembled units;-

and said-:units having means-fonsecurmg said-iner- 1161": Wall mediumthereto.-

6 A prei abricatedaform structure for;-.the ;1: ir.-., poses describedcomprising; an; assembly; of; hole low form wall units made of foldedsheetuma- 3 teria-l, certain of saidunits-being of substantially righttria-ngularcross sections and; other said: units being;ofsubstantiallyu-shapedecross'sec-a tion; said vright triangular unitsbeing; arranged}. inzpairswithztheir oblique panels. rearwardlypre-esentechand their end panels abutted:wherebmto.- forwardly; presenttheir remaining or'front panels; in:.a;common'pl,ane,' a U-shapedunitibeing'disposedintermediate r adjacent pairs. ofi thus. are

ranged right triangular units with: its open-face 7 0 disposed in theplane-of-said front panels of the: latter units-marginal portionswofisaid -thus;:ad--

joinedn units: being. foldedand interengaged'. to. provide uniting. .joint structures. .wire staplesoelb.

tendinglthroueh said'rjointstructurextozsecurertoa Tponerrts 8; Igether; the.-.-c0mponents i thereof; lock': barsdiseposed.nacross.--.thei front-.ofathe thus.- assembled units,coupleriloopserootedin said unit joint structures andsecured theretobycertain of saidwire staples, said ,7 coupler. loops-1 projecting. fromr the front ,face-..of:saideassembled'units so astorecei-ve-theeloclebars aandrthuslsecure the units thereto metallic. mesh forconcrete.reenforcemerit seeureddto .theouter edges-.ofsaid lock bars :to; extendacross lthetfront. of. the-assembled runits.

in.outwardly spacedrelationthereto, plaster supporting lathingl disposedacross the rear ofthe assembledtunits, each said unithavinga perpenedicular', sheet metahstriprcontiguous; to an inner surf-ace. .oiareap-face.portiomthereof, and said. strip havinehprongs struck outtherefrom .to proiect ithroughandlexteriorly of the unit material, said.prongsbeing clinched overrintovholding relae tion..to saidulathingclaim tfi-vwhereinwthesheet materialfrom whichtheuformewall".unitsd-are. made comprises waterproofedcorrugatedepaperboard, said paperboard being soddisp osed that. the.corrugations thereof extendrtransversely across. the; panels comprisingsaidrlunitsr SQApIefabriQated form structure as defined in:

c1aim 1'.wher ein.at least'one reenforcing' rod. is disposed'to extendperpendicularlywithin the in terionnfleachl .U-"shaped unit, and meansto support .lsa-idj'rodih. such position;

QTLInap efabIicated form structure as defined in claim5'wh'ereinzatfleast one reenforcing rod is disposed lto extendperpendicularly.withinthe interior oiifeachu shaped unit; and means tosup? port .saidrod in .such position:

10.? Inna. prefabricated form structure-as defined in;.claim.5'wherein.at .least 'ones-reenforcing' rod,-iis, di'Sposed .to extend pepfindicularly within- U.-shapectfunit"having h'anger means to. supportthe. containederod; and tie-members interconnestedrespeetivelmbetweensaid rod and the lock barsandb'etween.saidrod and arear sideportionofethe ,U.='sl1'ap,ed unit.

11. Iii-l arprefahricatedi form structure as definedinrlaim B'Avh'ereinat .least one reenforcing rodiis'udisposed Ito -extend1perpendicularlywithin the. interiorof leach. Ueshaped .unit; each said i uesh'apedlunitliaving, hanger meansv .to support the contained rod, and tie-membersintercone nectedlrespectively between said rod and the lock bars .-andbetween said rod .and theqsh'eet metal. strip..0.tlieuesh'apfi12...A,pi;eabricated form structure for the purposes.describedrcomprising an assembly-of hollow. formvwa-llunitsrmadeoi-folded waterproofedcorrugatedpaperboard .with.thecorrugations thereof disposed tr.ansverse.,toltheuverticallaxes ofsaid ;-units, certain of said units..being. ofsubstantiallyright..triangularicrosssection and'othersaid units beings of rsubstantially U-sh'a-ped cross. section,

saidrisht'triangular, .unit'sbeing. arraneedin. pairs withatheirroblique 1 panels ,rearwardly, presented andrtthelrt end-panels. abuttedwherebyto. forwardly;presentztheirr-remaining pr-front panels inalcommomplana. atueshaped unit being. disposed intermediate adjacent:pairs .01? thus arrangedz right trianguiartunitsewith its openface-disposed imthelplaneiof the frontpanelsof the latter units,marginaL-por-tions ;'-Of'I'1Sai'd" thus. adj oined units beingfolded:zandeinterengaged to' provide uniting J'oint-':strnctures,a.Wireestaples extending. through saidzrjoint istructuresstolsecure together.the com- 75 ,Aiprefabricated.formstructure asdefined in the interior,.of .each" ueshapedunit; each said.

othereofirglockl i bars disposed. across the;

front of said thus assembled units, coupler loops rooted in said jointstructures and secured thereto by certain of said wire staples, saidcoupler loops projecting from the front face of said assembled units soas to receive the lock bars and thus secure the units thereto, metallicmesh for concrete reenforcement secured to the outer edges of said lockcars to extend across the front of the assembled units in outwardlyspaced relation thereto, plaster supporting lathing disposed across therear of the assembled units, each said unit having a perpendicular sheetmetal strip contiguous to an inner surface of a rear face portionthereof, said strip having prongs struck out therefrom to projectthrough and exteriorly of the unit material, said prongs being clinchedover into holding relation to said lathing, at least one reenforcing roddisposed to extend perpendicularly within the interior of each U-shapedunit, each said U-shaped unit having hanger means to support 10 thecontained rod, and tie-members interconnected respectively between saidrod and the lock bars and between said rod and the sheet metal strip ofthe U-shaped unit.

- PAUL B. WEST.

REFERENCES CITED The following references are of record in the file ofthis patent:

UNITED STATES PATENTS

